Method for making a slip-resistant cover system

ABSTRACT

A method for manufacturing a decorative slip-resistant cover system includes the step of impacting a softened polymer film with a plurality of beads such that a section of each bead protrudes from the softened polymer film. The softened polymer film is hardened. The sections of the beads are embedded into an upper layer of the cover system.

This is a divisional application of U.S. Ser. No. 08/712,556, filed Sep.13, 1996, now U.S. Pat. No. 5,787,665, which is a continuation-in-partapplication of U.S. Ser. No. 08/431,823, filed May 1, 1995, now U.S.Pat. No. 5,613,332, which is a File Wrapper Continuation of U.S. Ser.No. 07/943,554, filed Sep. 11, 1992, now abandoned.

FIELD OF THE INVENTION

The invention relates to cover systems and method for making coversystems. Specifically, the invention relates to a floor system that canbe slip-resistant when wet and a method for making such a slip-resistantfloor.

DESCRIPTION OF THE BACKGROUND ART

Hard floor surfaces are, typically, durable and easily maintained. It isdesirable for floors in high traffic areas to clean easily and withstandyears of wear without losing their aesthetic appearance.

Ceramic tiles have been utilized for thousands of years to providedecorative hard floor surfaces. Ceramic tiles are secured to a basesurface by a fastening or adhesive agent. A grout or mortar is installedbetween the ceramic tiles.

Ceramic tiles and other hard floor surfaces are easily maintained andwithstand heavy traffic, but such floors can be slippery when soiled orwet. This problem is especially dangerous for floors in doorways,kitchens, and bathrooms where soil, such as oil, grease, sand, or water,can be deposited onto the floor.

The "slip resistance" of a floor can be increased by an abrasivesurface. Abrasive surfaces can be incorporated into certain floorsurfaces by mixing sand, aluminum oxide, carbide particles, or anothergrit in paint and painting the floor surface with the mixture. Thesurface coefficient of friction or "COF" of sand is higher than thesurface coefficient of friction for a painted surface. However, whensand is mixed into paint, the paint coats the sand and reduces thesurface coefficient of friction of the sand. An exposed surface of thesand can be provided to a floor surface by distributing sand onto a wetpainted floor surface. Such a non-slip floor surface does not resistheavy traffic and is not aesthetically pleasing. A sand-covered paintedsurface can be suitable for an exterior floor surface such as concrete,but it is undesirable for most interior floor surfaces. Interior floorsurfaces must withstand heavy traffic and an aesthetic appearance andfeel on, for example, bare feet. Painting an interior floor with agrit-containing paint is neither an effective nor an aesthetic solutionto preventing slipperiness on an interior floor surface.

U.S. Pat. No. 3,676,208 to Griffin discloses a floor surface whereinglass spheres are incorporated into a surface adhesive film. Anepoxy-type resin containing a significant concentration of minusculesolid spheres, such as glass beads, is coated onto a floor surface. Thisgrit-containing epoxy mixture increases the slip resistance of thefloor, but it does not provide sufficient slip resistance when heavilycoated with water or grease.

The background art of coating floor surfaces to increase slip resistanceis undesirable because the character of the floor surface is permanentlychanged. Coating a floor surface with a grit-containing paint makes thefloor surface abrasive. The abrasive surface traps dirt and can damagecleaning equipment.

The industry lacks an inexpensive cover system and, particularly, aslip-resistant floor that can be easily cleaned and quickly installed.

SUMMARY OF THE INVENTION

The invention is a cover system. The cover system includes a polymerlayer or adhesive film. The invention includes a plurality of sphericalparticles or "beads" partially embedded into the polymer layer.

The invention also includes a method for manufacturing a cover systemsuch as a slip-resistant floor. The method includes the steps ofimpacting a softened polymer film with a plurality of beads such that atleast one-half of an average volume or surface area of the bead embedsinto the softened polymer film. The softened polymer film is hardened orcured.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross section of a floor mat constructed accordingto the invention.

FIG. 2 illustrates a production line for incorporating a slip-resistantcoating onto a polymer film.

FIG. 3 illustrates a side view of a means for embedding beads into apolyurethane or similar polymer film or adhesive.

FIG. 4 illustrates a production line for adhering a backing compositionto the bead-coated polymer film of FIG. 2.

FIG. 5 illustrates a block diagram of the process for producing abacking composition.

FIG. 6 illustrates an application device for applying the backingcomposition to an underside surface of fiberglass.

FIG. 7 illustrates a production line for incorporating a decorativeslip-resistant coating onto a polymer film.

FIG. 8 illustrates a means for scanning a color image and generating acontrol output signal.

FIG. 9 illustrates a means for selectively ejecting beads into a polymerfilm.

FIG. 10 illustrates a cross section of the vibratory feeder plates andthe associated bead movement of FIG. 9.

DETAILED DESCRIPTION OF THE INVENTION

The invention is a cover system and a method for manufacturing the coversystem. The cover system includes a polymer layer or adhesive film.Desirably, the polymer film is integral or bonded to one side of a baselayer. The invention includes a plurality of spherical particles or"beads" partially embedded into the polymer film. When the cover systemis for use as a floor mat, the floor mat can provide a slip-resistantsurface having a decorative, colored design. The floor mat is especiallyuseful when an aesthetically pleasing slip-resistant floor is desiredsuch as on a boat or other vehicle or in a supermarket, hotel, orbathroom.

The invention is also a method for manufacturing a cover system such asa slip-resistant floor. The method includes the steps of impacting asoftened polymer film with a plurality of beads such that less thanone-half of an average volume or surface area of the beads protrudesfrom the softened polymer film. The softened polymer film is hardenedthermoplastic or cured thermoset. An embodiment of the method formanufacturing the cover system is desirable because an image can bescanned at a remote location and transmitted electronically to aproduction facility. The method for duplicating an image readily permitsthe production of a customized slip-resistant floor.

The preferred embodiment of the cover system is a fixed slip-resistantfloor. The fixed slip-resistant floor is preferred since it is installedpermanently and is used the same as any other flooring material. Thefixed slip-resistant floor can be installed to cover the floor surfaceof an entire room or only a portion of a room such as a walk path.However, the cover system with non-abrasive beads, such as plasticbeads, can provide a "self-lubricated" liner for slides and chutes invarious industries.

An alternative embodiment of the cover system is a rigid or firmportable floor mat. The floor mat is appropriate for relatively smallareas that are prone to becoming wet and/or greasy. Floor mats can beplaced in areas that are slippery without physically altering theoriginal surface of the floor or walkway. Floor mats can also be rolledup and set aside or removed in order to clean the floor.

Another alternative embodiment of the cover system is a padded floormat. The padded floor mat is the preferred embodiment of this invention.The padded floor mat has encapsulated closed cell foam and isshock-absorbing and suitable for areas of repetitive foot traffic, suchas behind bars, information booths, and customer service counters.

A monolayer of beads on a polymer film can be arranged in a random orderor in a multicolored image. The beads are embedded into the polymer filmso that at least one-half of each bead sinks into the polymer film. Thebeads can be embedded into a polymer film on a base layer of the coversystem. The base layer can be a multilayered laminate. A multilayeredlaminate has a polymer film in an upper layer. The beads are embeddedinto the upper layer of a multilayered web. The selection of the baselayer can be a belt or laminated material that determines the structuralcharacteristics of the final cover system.

The beads are deposited as a monolayer into the polymer film. Desirablepolymers for this polymer film include thermoplastic polymers,especially those of polyurethane.

The adhesion of the polymer film to the beads must be sufficient to holdthe beads during processing as well as later when in service. Also, thepolymer film or adhesive must be sufficiently fluid to enable the beadsto sink into it upon impact. The polymer film, however, cannot beadversely affected by process temperatures.

The thickness of the softened polymer film can be any thickness, but isdesirably more than the average diameter of the selected beads. Thepreferred embodiment of the invention includes a softened polymer filmthat is 60 percent to 90 percent of the average diameter of the beads.The section of the beads protruding from the softened polymer film isapproximately 40 to 10 percent of the average volume of the beads.

The beads can be any material that can be embedded into the softenedpolymer film. The beads used in cover systems for floors have asufficient coefficient of friction to provide a slip-resistant surface.The beads are, preferably, made of particles that have sufficienttoughness and hardness to resist wear. Desirable beads have anapproximate Mohs hardness of over 6.5 versus 5.5 for average glass.Also, desirable beads provide a coefficient of friction above 0.5 withboth leather and rubber when wet or dry.

The beads are approximately 10 to 40 mils in average diameter dependingupon the desired character of the cover system. Preferably, the beadsare approximately 20 to 30 mils in average diameter. A concentration ofapproximately 200 to 1,100 beads per square inch of this diameterprovide a sufficient coefficient of friction for a cover system. Apreferred concentration of beads of this diameter is approximately 600beads per square inch.

The beads for slip-resistant surfaces can be organic or inorganic,including a member selected from the group consisting of ceramics,flint, garnet, quartz, sand, and mixtures of these. Organic materials,including polymers, can be used as beads.

The beads of the preferred embodiment are semi-precious stone. Garnet ispreferred because it is hard, durable, inexpensive, and polished easily.Garnet, typically, has a Mohs hardness of approximately 8.

The beads of an alternative embodiment are quartz. Quartz is not as hardor as durable as garnet. However, quartz is available in a variety ofcolors.

The beads of another alternative embodiment are ceramic. Sinteredceramic beads are hard, tough, and exceptionally durable. Unlike mostother ceramic materials, ceramic beads are not friable. Sintered beadscan be produced with a controlled, textured surface by grinding theceramic material, pelletizing, and sintering the ceramic pellets in arotary kiln at about 2,500° F. The surface provides a high coefficientof friction without a "soil-holding grindstone-like surface." Theceramic bead surface can be varied from smooth to rough by particleselection and process temperature control to customize or balance slipresistance versus ease of cleaning. In contrast, aluminum oxide orcarbide particles in floor surfaces typically have sharp angular shapes,good for slip resistance, but very difficult to clean. The sinteredceramic beads have an approximate Mohs hardness of 7.5 and a diameter ofapproximately 20 to 30 mils. Some other desirable ceramic beads can benatural or synthetic ceramics, including a member selected from thegroup consisting of metal oxides, alumina, aluminum silicate, siliconcarbide, silicon nitride, and mixtures of these.

The cover system of another alternative embodiment of the invention is afirm floor mat. The upper polymer layer of the firm floor mat can bepolyurethane. Polyurethane is a desirable material for a cover systembecause polyurethane provides superior bead adhesion, excellenthydrolitic stability, toughness, and flexibility under a wide range oftemperatures.

The base layer of a multilayered laminate can include combinations ofnumerous materials. A lower layer of metal, ceramic, wood, and/or rigidpolymer provides tiles for a cover system. A lower layer of fiberglassand/or flexible polymer provides a flexible cover system. A lower orintermediate layer of a foam polymer provides shock-absorbing coversystem.

FIG. 1 illustrates a cross section of a floor mat 10 constructedaccording to the preferred embodiment of the invention. The floor mat 10includes a sheet of woven roving fiberglass 14 and a polyurethane layer16. The polyurethane layer 16 on one side is embedded with beads 12 andbonded to the beads 12. A backing composition 18 is bonded to the otherside of the polyurethane layer 16. An upper surface 9 of the floor mat10 is slip-resistant to foot traffic. An underside surface 11 of thefloor mat 10 has a tacky or adhesive characteristic to resist slidingagainst a floor surface. A high coefficient of friction on an uppersurface 9 results from the exposure of the crowns 12a of the beads 12above the polyurethane layer 16.

The polyurethane layer 16 has an initial thickness of 15 to 20 mils, butthe thickness changes as the result of displacement by the beads 12during the embedding procedure. The polyurethane layer 16 is, desirably,sufficiently thick to permit at least one-half of the surface area ofthe beads 12 to be embedded in the polyurethane layer 16. It ispreferable that the beads 12 be embedded from about 60 percent to about90 percent of their size or volume in the polyurethane layer 16. Thisrange of embedding permits approximately 10 percent to 40 percent of thevolume of the beads 12 to be exposed above the surface 9 of the floormat 10.

The upper surface 9 in this embodiment of the floor mat 10 has a textureor surface contour. The texture or surface contour results from thewoven roving fiberglass 14. The woven roving fiberglass 14 has a coarseweave of a crisscross pattern on its surface. The polyurethane layer 14partially assumes the crisscross pattern of the woven roving fiberglass14 and results in a wavy appearance in the upper surface 16a of thepolyurethane layer 14. The surface is also textured by the bead crowns12a of the beads 12. However, the transition from bead crowns 12a to theupper surface 9 of the polyurethane layer 16 is relatively smooth. Thesmooth surface prevents the capture of dirt or other matter.Accordingly, surface 9 of the floor mat 10 is easy to clean whileremaining slip-resistant.

The depth of the beads 12 can be varied depending upon the applicationof the cover system. If the beads 12 are embedded too deeply, the beadcrowns 12a are insufficiently exposed and slip resistance is decreased.If the beads are not embedded deep enough in the polyurethane layer 16,the upper surface of the floor mat 10 is rough and difficult to clean.Also, if the beads 12 are not embedded at least 50 percent of theirvolume into the polyurethane layer 16, the beads 12 can break loose fromthe floor mat 10. Properly embedded beads 12 remain incorporated in thepolyurethane layer 16 even when exposed to water, detergents, oil,grease, and the like.

The adhesion of the beads 12 can be improved by adding a silane, forexample, a γ-glycidoxypropyltrimethoxysilane, as a coupling agent. Acoupling agent bonds the beads 12 to the polyurethane.

The combination of the woven roving fiberglass 14 and the polyurethanelayer 16 as well as the polyurethane backing layer 18 provides the floormat 10 with significant shear strength and tear strength. The floor mat10 of this embodiment of the invention cannot be shredded, torn, orcracked during normal use. Further, the flexible and durable propertiesof the floor mat 10 remain in temperatures below -20° F., such as foundin walk-in freezers.

The woven roving fiberglass 14 in the preferred embodiment of theinvention is at least 16 ounces per square yard and, preferably, 18ounces per square yard. The woven roving fiberglass 14, desirably, has a"tight" 5 by 7 weave of machine direction by cross-machine direction. Afiberglass layer of eight ounces or less per square yard provides littleresistance to shearing when saturated with resin. Saturation of bothsides of the woven roving fiberglass 14 with polyurethane forms animpermeable and a relatively non-porous floor mat 10.

FIG. 2 illustrates a production line for the floor mat 10. A roll ofwoven roving fiberglass 14 is fed in an overlapping relationship with aroll of thermoplastic polyurethane layer 16. The two sheets traveltogether through a first heater 20 located between rolls 22 and 23. Thefirst heater 20 heats the polyurethane layer 16 to about its transitiontemperature or melting point. The heating of the grade of polyurethanelayer 16 used in this embodiment of the invention is at a maximumtemperature of about 425° F. The first heater 20 heats the two layers byconvection heat for a period of time sufficient to bond the two layerstogether.

The "combination web" of the woven roving fiberglass 14 and thepolyurethane layer 16 passes along the line to a means for embeddingbeads 30. The beads 12 are partially embedded into the polyurethanelayer 16 by the means for embedding beads 30.

The combination web travels around a roll 24. The tension of thecombination web about roll 24 can be used to apply pressure to the beads12 and further embed the beads 12 into the polyurethane layer 16. Thecombination web then enters a second heater 40. The second heater 40adjusts the depth of immersion of the beads 12 within the polyurethanelayer 16 and controls the rate of absorption of the polyurethane layer16 into the woven roving fiberglass 14. The second heater 40 heats thecombination web to a maximum of temperature of about 425° F. and softensthe polyurethane layer 16 such that approximately 60 percent to 90percent immersion or embedding of the average volume or surface area ofthe beads 12 into the polyurethane layer 16 occurs. The furtherimmersion of the beads 12 into the polyurethane layer 16 is accomplishedby gravity in this embodiment of the invention.

The operational temperature of the second heater 40 is a temperaturesufficient to bond the layers of the combination web. A radiant heatercan be used that heats the surface of the polyurethane layer 16 to amaximum temperature of 425° F. for a short period of time or, forexample, one-half minute. The exact time and temperature are set inaccordance with the materials being processed.

It is undesirable for the polyurethane layer 16 to become so hot as tobe completely absorbed into the woven roving fiberglass 14. Theunderside surface 11 of the woven roving fiberglass 14 can remainpartially unsaturated to assist with later bonding to a backingcomposition. Insufficient absorption, however, can cause voids or allowfibers of unsaturated fiberglass to protrude from the product. Atemperature differential of at least 36° F. between the upper surfaceand the underside 15 of the woven roving fiberglass 14 is desirable forproper saturation.

The combination web of woven roving fiberglass 14 and polyurethane layer16, upon exiting the second heater 40, is permitted to cool so that thebeads 12 set in the hardened polyurethane layer 16. The product passesover roll 47 to a take-up roll 48.

An alternative embodiment of the invention embeds the beads 12 in asimple geometric pattern. A stationary mask (not shown) having aplurality of slots extending in the direction of the path of travel ofthe combination web, can be placed between the cloud of beads 12 and thepolyurethane layer 16. The slots in the mask impart a striped pattern ofbeads onto the surface of the polyurethane layer 16. Another embodimenthas a mask that moves at the same speed as the combination web. Thismoving mask is between the cloud of beads 12 and the polyurethane layer16. A moving mask imparts a design, such as a tile pattern, onto thecombination web. This moving mask can be on a conveyor belt that passesin close proximity to the polyurethane layer 16.

FIG. 3 illustrates the combination web of woven roving fiberglass 14 andpolyurethane layer 16 exiting the first heater 20. The combinationpasses along the line to a means for embedding beads 30. Thepolyurethane layer 16 reaching the means for embedding beads 30 is softand tacky and faces downward into a bead slinging containment area 31.

A paddle wheel 32 travels within the bead slinging containment area 31in the direction of the arrow as shown. The paddle wheel 32 projectsbeads 12 from the bottom of the bead slinging containment area 31 andimpinges the beads 12 into the polyurethane layer 16, thereby embeddingthe beads 12 in the polyurethane layer 16.

A desirable dispersion of bead density is between 200 beads per squareinch and 1,100 beads per square inch. The selection of the surfacecharacteristics of the beads 12 and of the density of the beads 12embedded in the polyurethane layer 16 determines the slip resistance ofthe resulting floor mat 10 as well as the ease of cleaning of the floormat 10. Controls (not shown) are incorporated in the means for embeddingbeads 30 to enable accurate adjustment and control of the dispersion ofbead density.

The feed rate of beads 12 is controlled by the speed of rotation of feedbar 35. As the beads flow from the hopper 34 along the sloped surface31b of the containment area, they are fed past the rotating bar 35 intothe bottom of the bead slinging containment area 31. Rapid rotation of apaddle wheel 32 causes the paddles 33 to strike the beads 12 and throwthe beads 12 upward into the polyurethane layer 16.

The rotation of the paddle wheel 32 creates a cloud of beads 12. Most ofthe beads 12 impact the polyurethane layer 16 and are embedded therein.A number of the beads are thrown into a first baffle plate 36 or evenfurther into a second baffle plate 37. The first baffle plate 36prevents the beads from ejection from the bead slinging containment area31. The angle of the baffle plate 37 can be adjusted to cause deflectedbeads to land upstream of feed bar 35 or downstream therefrom. Thedeflected beads 12 are directed upstream of the feed bar 35.

The non-embedded beads are removed from the cloud of beads 38 by thepaddle wheel 32 and fed into the bottom of the bead slinging containmentarea 31. The speeds of the rotating feed bar 35 and the paddle wheel 32as well as the angle of the second baffle plate 37 permit adjustment orcontrol in the density of the cloud of beads 38. An even dispersion ofthe beads 12 across the width of the traveling polyurethane layer 16 isachieved by maintaining a constant supply of the beads 12 across thewidth of the paddle wheel 32 from a supply hopper 34. An even dispersionof the beads 12 across the width of the floor mat 10 provides a constantcoefficient of friction on the surface of the floor mat 10.

FIG. 4 illustrates a production line for adhering a backing composition18 to the underside 15 of woven roving fiberglass 14 to complete thefloor mat 10. The bead-embedded combination web of the woven rovingfiberglass 14 and polyurethane layer 16 in the "let-off roll" 48 isunrolled onto a table 51. The backing composition 18 is then appliedthrough a mixer nozzle 52. Once the backing composition 18 is applied tothe underside 15 of the woven roving fiberglass 14 of the combinationweb, the composition is smoothed by cable smoothers 53. The cablesmoothers 53 are cables stretched across the width of the table 51 andslightly submerged into the backing composition 18. The backingcomposition 18 at this stage is liquid and the cable smoothers 53flatten the liquid and release gas bubbles from the backing composition.A blower 54 distributes a jet of air onto the surface of the backingcomposition 18 and further removes air bubbles from the backingcomposition 18. Downstream from the blower 54 is a curing station 55.The curing station 55 includes a TEFLON® brand or otherfluorohydrocarbon roller belt 56 and a heater block 57. The height ofthe roller belt 56 can be adjusted to provide a selected thickness ofthe backing composition 18. The thickness of the backing composition 18is, preferably, 50 to 100 mils depending upon the intended applicationof the floor mat 10.

The roller belt 56 maintains pressure on the backing composition 18 asthe backing composition 18 passes over the heater block 57. The heaterblock 57 is a conduction heater and provides heat to the polyurethanelayer 16 at a relatively low temperature or, for example, 160° F. Theheater block 57 can be heated by hot water or electricity.

The backing composition 18, upon exiting the curing station 55, iscured, and the floor mat 10 is complete. The completed floor mat 10 iswound around another take-up roll 60. In order to provide commerciallymarketable floor mats, the edges of the floor mats are trimmed, and thefloor mat is cut into selected lengths.

FIG. 5 illustrates a block diagram of the process for producing thebacking composition 18. The ingredients for the backing composition 18are mixed in a mixer 61. A polyol is mixed with a filler, such as clayor calcium carbonate. The additives to the polyol must be as dry aspossible to prevent the formation of gas bubbles when mixed withisocyanate. A color additive can also be added to the mixture. The mixer61 is a high shear mixture that homogeneously combines the addedingredients. The mixture is pumped from mixer 61 into a first tank 62and forms a first part of a two-part polyurethane backing composition.

The second part of the two-part polyurethane composition is isocyanateand is contained in a second tank 63. Upon application of thepolyurethane backing, the isocyanate from the second tank 63 and thepolyol mixture from the first tank 62 are pumped through meter pumps 64in controlled quantities and mixed together by the static mixer 52.Commercially available polyurethanes can be applied as the backingcomposition. Polyurethane mixtures are heat curable at varioustemperatures.

Desirable embodiments of the invention apply a 50 to 100 mil mixture ofisocyanate and polyol or "backing composition" to the underside 15 ofthe woven roving fiberglass 14. Curing temperatures for such backingcompositions are from ambient temperature to about 180° F. The backingcomposition 18 in desirable embodiments of the invention is applieddirectly to the underside 15 of the fiberglass in the combination web.

FIG. 6 illustrates an application device for applying the backingcomposition 18 to the underside of the combination web. A nozzletransport means 70 reciprocates across the width of the table 51. Thestatic mixer nozzle 52 is mounted to a carriage 71 and is guided inmovement along a shaft 72. The reciprocating movement of the carriage 71is performed by joining the carriage 71 to a chain 73 at a pin joint 74.The pin joint 74 travels within a slot 75 in the carriage 71. The chain73 travels between two sprockets (not shown) as the pin joint 74reciprocates within slot 75 in the direction of the arrows as shown inthe figure. The reciprocating motion of the mixer nozzle 52 forms azigzag pattern on the woven roving fiberglass 14 of the combination web.This pattern is pressed by the cable smoothers 53 and is not noticeablein the final product. Alternative devices to the nozzle transport means70 can be used.

The backing composition 18 has a rapid curing time after mixing in thestatic mixer nozzle 52. For this reason, the backing composition isdeposited directly onto the fiberglass instead of the conventionalmethod of coating a moving fiberglass web through a resin. Theconventional method does not remove trapped air from the nonporouspolyurethane layer 16. Trapped air can produce delamination of thebacking composition and cause porosity in the finished mat.

FIGS. 7 through 14 illustrate the device and method for applying adecorative pattern of beads onto a slip-resistant cover system. Certainembodiments of the decorative slip-resistant cover system can usesmaller beads than those described above.

FIG. 7 illustrates a production line for incorporating a decorativeparticulate coating onto a polymer film. The components of thisproduction line are identical to those components described for FIG. 2except that the means for embedding beads 30' applies a decorativepattern of beads 12 to the polymer layer 16. The means for embeddingbeads 30' is a means for selectively ejecting beads of different colorsand/or sizes. The means for embedding beads 30' receives control signalsfrom a microprocessor (not shown) and distributes the beads 12 accordingto their size and/or color.

FIG. 8 illustrates a device for scanning a colored image and generatinga control output signal for that image. A conventional scanner 100 isused to scan an image such as a colored image 102 by moving a scannersensor 104 over the colored image 102. The scanner 100 generates acorresponding image and transmits that image to a conventionalmicroprocessor 106. Conventional software can operate the scanner 100and the microprocessor 106. The Mustek company manufactures a scannerthat reads an 81/2 by 11 inch area. Alignment of a plurality of thesesscanners can cover large areas. The data from the scanned area can thenbe oriented in the microprocessor.

The microprocessor 106 arrays the total image into a grid having aplurality of two-dimensional sectors. The two-dimensional sectors arepreferably in the shape of squares. The microprocessor 106 converts thecolor of the scanned image in each sector into a corresponding primarycolor. The microprocessor 106 generates a control output signal for eachcolor in each grid sector. The control output signal is responsive tothe primary color of the converted, scanned image in each sector.

The microprocessor 106 can transmit the control output signals through amodem 108 and telephone lines, if necessary, to a local microprocessor110. The local microprocessor 110 is located in the cover systemmanufacturing facility. The local microprocessor 110 transmits controloutput signals through cables 112 to the amplifiers 114. The amplifiers114 feed control signals to the dispersing solenoid valve via lines 118.The Aro company manufactures a valve that operates at over 60 cycles persecond at 100 p.s.i. with a life of over 20 million cycles.

The amplified signals are isolated from the unamplified control outputsignals by an integrated circuit (not shown). The isolation of thecontrol output signals in this manner prevents an electrical surge fromdamaging the local microprocessor 110.

The number of valves required by particular embodiments of the inventioncan be simplified. Simplification can be accomplished through a datahighway. The DeviceNet product sold by the Allen-Bradley companyestablishes one wire communication from their PLC or pneumatic logiccontroller to a manifold of a plurality of solenoids.

FIG. 9 illustrates a means for selectively ejecting beads into a polymerfilm 160. A plurality of hoppers 120 are arranged in a row. Each hopper120 contains a single color of beads 12. Each hopper 120 contains beads12 of a different color and/or size from the beads 12 contained inanother hopper 120. The polyurethane layer 160 is conveyed beneath therow of hoppers 120. The microprocessor 110 is programmed to actuate thesolenoid valves 116 that direct proportional amounts of air to locatebeads to fill each pixel in layer 160 with the correct color spacing andnumber of beads.

The beads move from the bin 120 into a vibrating feeder 134 in adirection shown by the dotted lines. The Syntron company manufacturesvibrating feeders suitable for use with the invention. The table conveysan even layer of the beads and moves the beads forward one bead deep inan orderly controlled motion towards the return bin 135. The velocity ofbead ejection is controlled by amplitude and/or frequency of vectors.The beads fall at the end of the table into the bin 135 and are returnedto the hopper 120 or are directed forward 137 into the locating chute132 by a small jet of controlled gas, such as air, from nozzles 133. Airis fed from a line 139 into solenoid valves 116 controlled by amicroprocessor 110 to nozzles 133 via lines 130. Beads of a singlecolor, from one hopper or multiple colors from several hoppers can bedropped through the locating chute 132 onto the vibrating collectorfeeder 136.

FIG. 10 illustrates a cross section of the vibratory feeder plates andthe associated bead movement of FIG. 9. The movement of the feeder 136is similar to the movement of the feeder 134. Both feeders move forwardand control the flow and the spacing of the beads from the end of thefeeder 136 into the softened polymer 160. The preferred embodiment ofthe invention uses a three-foot wide transfer web with pixelsone-quarter inch square. This arrangement requires 144 pixels withaccompanying control valves and nozzles per color of beads. A polymerweb running at 30 inches per minute requires a single bead control jetof air every one-half second. Higher web speeds and/or smaller pixelswith greater design detail can be achieved by modifying this basicstructure. Bead colors can be primary colors so that a scanned image 102is duplicated in a corresponding color pattern of beads 160 with morethan one color per pixel.

I claim:
 1. A method for manufacturing a cover system comprising:embedding a plurality of beads into a polymer film; setting said embedded beads into said polymer film whereby a substantial concentration of said embedded beads have less than one-half their surface area exposed protruding from said polymer film; curing or hardening said polymer film; wherein said embedding of said beads forms a pattern on said polymer film; and wherein said embedding includes filtering said beads through a mask.
 2. The method of claim 1 wherein said embedding includes embedding at least two groups of beads having different colors.
 3. The method of claim 2 wherein said embedding includes embedding at least two groups of beads having different sizes.
 4. A method for manufacturing a cover system comprising:embedding a plurality of beads into a polymer film; setting said embedded beads into said polymer film whereby a substantial concentration of said embedded beads have less than one-half their surface area exposed protruding from said polymer film; curing or hardening said polymer film; wherein said embedding of said beads includes embedding at least two groups of beads having different colors and forms a pattern on said polymer film with respect to said colors.
 5. The method of claim 4 further comprising a first step of:forming a base layer, said base layer having a first side and a second side, said polymer film being bonded onto said first side of said base layer.
 6. The method of claim 5 further comprising a final step of adhering a backing composition onto said second side of said base layer.
 7. The method of claim 4 wherein said embedding includes embedding at least two groups of beads having different sizes.
 8. A method for manufacturing a cover system comprising:embedding a plurality of beads into a polymer film; setting said embedded beads into said polymer film whereby a substantial concentration of said embedded beads have less than one-half their surface area exposed protruding from said polymer film; curing or hardening said polymer film; further including:scanning an image; transmitting said scanned image to a central microprocessor; arraying said image into a grid including a plurality of two-dimensional sectors; generating a control output signal for each grid sector responsive to said image in each grid sector; orienting, controlling, and positioning said beads with vibratory feeders; directing said beads from said vibratory feeders to said polymer film using a pneumatic nozzle; converting said control signal into a proportional pneumatic output to control the directing of said beads according to characteristics of said beads for each grid sector; and wherein said embedding includes embedding said beads to reproduce said scanned image.
 9. The method of claim 8, wherein said scanning includes scanning said image at a remote location from said central microprocessor and said transmitting of said scanned image is via a modem connection to said central microprocessor.
 10. The method of claim 8, wherein said embedding includes embedding at least two groups of beads, each group having at least one of different colors and different sizes as said characteristics of said beads. 